3. 6
INTRODUCTION
5S Is a simple but highly effective set of
techniques that remove waste from your
work environment through better workplace
organization, visual communication and
general cleanliness.
The pillers of 5S are defined as Seiri,
Seiton, Seiso, Sheketsu, and Shitsuke.
Because each of the five pillars begins with
“S”, this method was appropriately names 5S.
4. 7
BACKGROUND
Developed by the Japanese
Workplace Organisation and
Housekeeping System
Helps Create a Better Working
Environment and a Consistently
High Quality Process
5. 8
WHY TO IMPLIMENT 5S?
Implementing 5S across the organization will:
Change the mindset of employees and facilitate
continuous improvement
Improve the efficiency of employees and make them
more productive
Eliminate time spent on non-value-added work
affecting individual and workplace efficiency
Create a robust foundation for future work in the
quality arena
As a matter of fact, before implementing any other
quality methodology, organizations should implement
and institutionalize 5S.
6. 9
5S PRONCIPLES
SEIRI – Organisation – Sort
SEITON – Orderliness – Set in Order
SEISO – The act of Cleaning – Shine
SEIKETSU – The State of Cleanliness –
Standardize
SHITSUKE – The Practice of Discipline -
Sustain
7. 10
5S PRINCIPLES
Sort – Clearing the work area
Any work area should only have the items needed to perform
the work in the area. All other items should be cleared
(sorted out) from the work area.
Set In Order – Designating Locations
Everything in the work area should have a place and
everything should be in its place. The needed items should
be kept in the correct place to allow for easy and immediate
retrieval.
Shine – Cleanliness and workplace appearance
The third pillar of 5S helps to keep work areas, all work
surfaces and equipment clean and free from dirt, debris, oil,
etc.
8. 11
5S PRINCIPLES
Standardize : Everyone doing things the same way
Everyone in the work area and in the organization must
be involved in the 5S effort, creating best practices and
then getting everyone to “copy” those best practices the
same way, everywhere, and every time. Work area
layouts and storage techniques should be standardized
wherever possible.
Sustain : Ingraining the 5S’s into the culture
SUSTAIN is the last pillar of 5S and drives the
organization to be disciplined in maintaining these new
standards and procedures and in continuously improving
the 5S state of the workplace.
9. 12
5S PRINCIPLES & ACTIONS
Step Name Action
1
2
3
4
5
Sort
Set
In
order
Shine
Standardize
Sustain
Sort out unnecessary items in the work-place
And discard them.
Arrange necessary items in good order so that
They can be easily picked for use “A place for
Everything Every things in its place.”
Clean your workplace completely so that there is
No dust on floor, machine or any other area
Under consideration
Maintain high standard of housekeeping and
Workplace organization at all times.
Train people to follow good house keeping disciplines.
10. 13
5S BENEFITS
1. Sales – Increase sales (market share).
2. Savings – Save costs.
3. Safety – Provide a safe working
environment.
4. Standardization – Standardize the
operating procedure.
5. Satisfaction – Employees and
customer satisfaction
11. 14
5S BENEFITS
The 5S’s lead to improve processes and ultimately:
Reduced set-up times
Reduced cycle times
Increased floor space
Lower safety incident/accident rate
Less wasted labor
Better equipment reliability
12. 15
WHEN TO IMPLIMENT 5S
Space is crowded with parts and tools
Unneeded items are stacked between
workers
Excess inventory on the floor
Excess items and machines make it difficult to
improve process flow
Equipment is dirty and a collection point for
miscellaneous materials
Needed equipment such as tools are difficult
to find
13. 16
CHECKLIST FOR ASSESMENT
Questions
Do people in your departments struggle to locate
drawings, specifications, tools, dies and so forth ?
Are there items in your departments such as files,
documents, and equipment, tools, that do not have an
owner ?
Are there customer drawings, customer samples, old
magazines or telephone directories, in your workplace
that are not used and are gathering dust ?
Is there any safety equipment, such as fire
extinguishers, lying around that is pass its expiration
date ?
14. 17
CHECKLIST FOR ASSESMENT
Question
Are there loose hanging naked electrical wires in the
department / organization ?
Do visitor and customers struggle to reach the right
person or department in your organization ?
Are there files in the department that are old, unlabeled,
and torn ?
Are there instances of running out of raw material,
consumables, stationary and other items ?
Do you observe materials, tools, consumables, files,
drawings and so forth getting mixed up ?
Do you observe valuable space being occupied by
useless and unwanted items ?
15. 18
SEIRI – SORT
Seiri is distinguishing or sorting
out between wanted and
unwanted items in a place and
removal of the unwanted such a
place can be a shop floor, an
office, a house or a hospital.
16. 19
HOW TO IMPLIMENT SEIRKI
Some typical areas where Seiri might be applied
include work in process, unnecessary tools, unused
machinery, defective products, and paper and
documents.
Separate needed items from unneeded items.
Remove unneeded items from working areas
Item never used : Discard
Item not needed now : Store them.
Remove all excess items from working areas,
including work pieces, supplies, personal items, tools
instruments, and equipment.
17. 20
HOW TO IMPLEMENT SEIRI
Use red tag to get rid of unneeded items.
Store items needed by most people in a
common storage area.
Assign a person to organize and manage the
common storage area.
Store items only needed by each individual in
his/her own working area.
Organize working / Storage area.
18. 21
RED TAGGING
The Red-Tagging Strategy is a simple method for
identifying potentially unneeded items in the factory,
evaluating their usefulness, and dealing with them
appropriately.
It is simply putting Red tags on items in Factory that
need to be evaluated as being necessary or
unnecessary.
An Item with Red-Tag is asking 3 Questions.
Is this Item needed ?
If it is needed, is it needed in this quantity ?
If it is needed, does it need to be locate here ?
19. 22
CHECK POINTS
Throw away/return things which are not needed
Paperless and Re-cycle Bins for papers, bottles, etc.
“Needed things” stored : low, medium & high usage
Personal belongings kept to the minimum
Treat defects, leakage, breakage and their causes
One-is-best
Daily “Things-to-do” List
One set of tools/stationary/1-page form
One hour meeting
One stop service for customer
One location file (e.g. LAN Server)
20. 23
ADVANTAGES OF SEIRI
Saving in use of space.
Removal of excess equipments/parts.
More space made available in filling cabinet/shelf.
Avoidance of error.
Eliminate unsafe situations.
Easy access to things.
Preventing rusting or damage to materials.
Reduced inventory by sales of scrap material/excess
materials.
Easy available of material.
21. 24
SEITON
Seiton means to prepare correctly or straighten.
This should be understood as organizing
correctly following correct method. This means
that maintaining things in the right way.
SEITON implies arranging necessary items in
good order so that they can be easily picked for
use. Implementing SEITON means that every
thing should be kept in its place only after use
22. 25
SEITON
First we should decide where things belong and
every thing should have a place only after use.
This will help us to pick things needed without
wasting time on searching for them.
Three rules to be followed for implementing
SEITON
Decide where thing need to be placed
Keep the things in that place
Always follow the system.
23. 26
WHY SEITON
Needed items can be easily
found, stored and retrieved.
First-in First-out (FIFO)
Save space and time.
24. 27
GUIDELINES
A Place for everything and everything in its place.
Place tools and instructional manual close to the
point of use.
Layout the storage area along the wall to save
space.
Place items such that they are facing toward
passage for easily access.
Store similar items together. Different items in
separate rows.
Don’t stack items together. Use rack or shelf if
possible
25. 28
GUIDELINES
Use small bins to organize small items
Use color for quickly identifying items.
Clearly label each item and its storage areas
(lead to visibility).
Use see-throw cover or door for visibility.
Use special designed cart to organize tools,
jigs, measuring devices, etc., that are
needed for each particular machine.
26. 29
HOW TO IMPLIMENT SEITON
Get rid of unnecessary things.
Prepare storage areas, reassign spaces, racks, cabinets
etc.,and provide for the minimum of additional storage
facilities.
Decide the place for every thing frequently used items
close by at an easily accessible height. Decide how
thing should be put back.
Tag/sign/label are required for each location of that
material / equipment. Even if some items are needed
for temporary use their storage place is to be decided
and proper indication to be made put a board indicating
that they are temporarily stored.
27. 30
HOW TO IMPLIMENT SEITON
Color coding, arrows, lamps, etc., to be used for quick
identification, indication is required for out of stock, some
body using it or lost etc.,
Define working area, path, entrance / exit lines, door
opening lines / traffic flow lines / storage space lines etc.,
Make the system to function with minimum need of tools
e.g., use wing nuts wherever possible to avoid need of
spanners.
Display cautions, messages and instructions in proper
height and written neatly so that people can see from a
distance.
All fixed location and color coding should be documented.
Frequent inspection is required.
28. 31
CHECK POINTS
Everything has a clearly designated name & place
Every place should have a ‘responsible person’ label
Eliminate unnecessary covers and locks
Functional placement for leaflets, tools and material
Filing standards and control master list
First in, first out arrangement
Zoning and placement marks
Neat notice boards (also remove obsolete notices)
Easy-to-read notices (including zoning)
030-second retrieval of tools, document & parts
29. 32
BENEFITS OF SEITON
Help reducing time consumed in searching material
for use.
Easy to inspect and recognize when material are
taken out from their location.
Creates work effectiveness.
Creates safety atmosphere.
Help in inventory control.
Better identification by using color coding.
Improves workplace utilization.
30. 33
SEISO
Seiso means take up the job
of cleaning SEISO insist to
clean the workplace
completely so that there is
no dust on floor, machine, or
any other place under
consideration.
31. 34
OBJECTIVES
Cleanliness ensures a more comfortable
and safe working place.
Cleanliness will lead to visibility so as to
reduce search time.
Cleanliness ensures a higher quality of
work and products.
32. 35
GUIDELINES
Use dust collecting covers or devices to prevent
possible dirt or reduce the amount of dirt.
Investigation the causes of dirtiness and implement
a plan to eliminate the sources of dirt.
Cover around cords, legs of machines and tables
such that dirt can be easily and quickly removed.
Operators clean their own equipment and working
area and perform basis preventive maintenance.
Keep everything clean for a constant state of
readiness.
33. 36
GUIDELINES
Individual cleaning responsibility
assigned
Make cleaning and inspection easier
Clean even the places most people do
not notice
Cleaning inspections and correct minor
problems
Regular sparkling cleaning campaigns.
34. 37
CHECK POINTS
Transparency (e.g. Glass covers for see-through)
Straight line and right-angle arrangements
‘Danger’ warning signs and marks
Fire extinguisher and ‘EXIT’ signs and safety
device
Work instructions and ‘passed’ labels
Electrical wiring neatness and switch labels
Energy Preservation – AC Temp. mark/switch
Color-coded gangways/pipes and directional
marks
35. 38
CHECK POINTS
Color coding – paper, files, containers, etc.
Responsibility labels on floor plan or at sits.
Prevent noise and vibration at source
Department/Office labels and name plates
Park-like environment (garden office/factory)
36. 39
SEIKETSU
Seiketsu means maintaining high
standards of house keeping and
workplace organization at all
times.
37. 40
GUIDELINES
Workers should make it a habit to be clean and tidy
(starting with themselves). Here are some things
that workers have done under the heading of
standardized clean-up:
Removing used, broken, or surplus items from the
work area
Marking safety a prime requirements by paying
attention to noise, fumes, lighting, cables, spills,
and other aspects of the workplace environment
Checking that items are where they should be
38. 41
GUIDELINES
Listening to the “Voice” of the process and
being alert to things such as unusual noises
Ensuring that there is a place for everything
and that everything is in its place
Wearing safe working apparel and using safe
equipment
Minimizing all waste and the use of valuable
resources such as oil, air, steam, water, and
electricity
40. 43
GUIDELINES
No matter how often the 5 S’s were
implemented, 5S conditions would fall apart in no
time and the workplace would be dirty and
chaotic again.
Unneeded items would being to pile up as
before.
Tools, brooms, shovels, dies, etc. would not get
returned to their proper place and we would be
forced to run all over the place trying to find
them..
No matter how dirty equipment became, little or
nothing would be done to clean it.
41. 44
GUIDELINES
Team members would neglect to wear safety
equipment or leave things on the floor and an
injury would occur.
Dirty machines would start to malfunction and
produce defective parts.
Dirt from the floor would spread to the work area
itself and cause defects.
Dark, dirty disorganized work areas would lower
morale.
Customers would become disgusted by the dirty
conditions and look for someone else to do their
products.
42. 45
CHECK POINTS
Execute individual 5-S responsibilities
Wear, if necessary, safety helmet/gloves/shoes/etc.
Good communication and telephone practices
Daily 5-minute 5-S practice
One day processing of job/tasks
Practice dealing with emergencies
Organization Chart and Performance Indicators
Design and follow the 5-S Manuals
Quarterly 5-S Audit and improvements
Seeing-is-believing : check for 5-S environment
43. 46
IMPLEMENTATION OF 5-S
Organize the program committee. (PLAN)
Develop a Plan for each S (PLAN)
Announcement for the start of the programme (DO)
Provide Training & Education to employees. (DO)
Select a day and everybody cleanups his/her own
working area (DO)
Select a day and everybody organizes his/her own
workplace.(DO)
Evaluate the results of 5S.(CHECK)
Self Examination and take corrective action.
(ACTION)
44. 47
EXERCISE-QUALITY DEPT.
SORT.
Cleaned Out unneeded item stored in the QA Lab.
Cleaned out all needed items in QA Lab (for relocation).
Remove unneeded files and documents in QA Filing System.
SET IN ORDER.
Organize retained items in QA Lab and QA Inspection Area.
Segregate and Label the majority of gages used for inspection.
Move an additional worktable to the QA Lab to aid in
streamlining the first part inspection process.
Label items and areas in the QA Lab.
Organize filing cabinets in a logical manner.
Labeled files and file drawers.
45. 48
EXERCISE-QUALITY DEPT.
SHINE
Painted the QA Lab walls, shelving and inspection table.
Repair and paint the carts used for Final Inspection Areas.
STANDARDIZE
Standardized the documents and equipment needed for first part
inspections.
Arrange and Label gauges.
Standardize QA files.
SUSTAIN
Revise QA Weekly Check Sheet to include inspections of
items covered in the QA 5S event.
49. 52
INTRODUCTION
“Kai” in Japanese Language means
“Change” and
“Zen” means “Good”
The literary meaning of Kaizen is
“change for good”
50. 53
INTRODUCTION
Kaizen is the Japanese philosophy of
continuous improvement by all the employees
in an organization so that they perform their
tasks a little better each day.
It is a never ending journey centered on the
concept of starting new each day with the
principle that the methods can always be
improved.
51. 54
INTRODUCTION
Kaizen is the philosophy of continual
improvement, that every process
can and should be continually
evaluated and improved in terms of
time required, resources used,
resultant quality, and other aspects
relevant to the process.
52. 55
INTRODUCTION
When Applied to the workplace, Kaizen
means continuing improvement
involving everyone – managers and
workers alike.
Kaizen is not limited to manufacturing
systems only. It also means continuing
improvement in personal life, home life,
social life, and working life.
53. 56
KAIZEN BENEFITS
Problems are identified at source and resolved.
Small improvements which are realized can add
up to major benefits for the business
Improvements, which lead to changes in the
business quality, cost and delivery of products,
mean a greater level of customer satisfaction,
and business growth.
By involving employees in looking at their
environment to bring about change, results in
improved morale as people begin to find work
easier and more enjoyable.
54. 57
5 W AND 1 H OF KAIZEN
What is Kaizen ?
Who should do Kaizen ?
Why should we do Kaizen ?
When should we do Kaizen ?
Where should we do Kaizen ?
How can we do Kaizen ?
56. 59
CHANGE TO FACE WITH
Competitors becoming increasingly
hostile – pressure on price
Changes in the market place (eg.
Liberalization of government policy)
Cheaper overseas products and relaxed
imports
New environment / safety rules
Globalization
57. 60
FUTURE
In future, organizations will be based on
knowledge and not just physical assets
such as Land or Products.
The most important employees will be
‘Knowledge workers’ and employees will
be judged on their ability to acquire
knowledge.
‘Knowledge will be the key’
58. 61
RESPONSE TO CHANGE
Kaizen : A Response to the Changing Environment
We must change
Our way of thinking
Our way of doing things
If we don’t move forward, we will move backward
59. 62
WHY KAIZEN ?
To remain Competitive.
Nothing will give more satisfaction,
motivation than seeing our ideas
implemented.
To improve our quality of work-life.
To improve our customer service.
To work smarter, not harder
60. 63
WHAT IS KAIZEN
Kaizen is basically small Continuous
improvements carried out by a person
who is doing the job, in his/her day to
day work.
Who decides what is a kaizen ?
The person who has done it.
61. 64
EXAMPLE OF KAIZEN
ROUTINE WORK
New way of filing that saves searching time
Use of devices to save time and reduce fatigue
Rearrange work elements
NORMAL (EXPECTED) WORK
Daily filing of papers
Disposal of old files
Learn new PC tools
62. 65
EXAMPLE OF KAIZEN
IMPROVEMENT (IN OWN AREA)
Dispatch clerk rationalizing postage envelops
Operator inventing a method to load multiple
pieces at a time
IMPROVEMENT (IN OTHER’S AREA)
Workman suggesting method to eliminate
rejection
Idea about how to save energy cost in company.
63. 66
THE CONCEPT OF 3 Mus
Here are expressions of problems :
Muda – Waste – Activity that does not add
value to the job – Non – value added,
unnecessary, avoidable
Mura – Inconsistency – Not uniform in size,
strength, ability, value, rank, number, etc.
Muri – Strain – Excessive exertion / tension,
demand on one’s emotions
64. 67
MUDA
Things that do not help anything
Things that are not profitable
Unprofitable actions are…
Work procedures that make you stack or
rearrange materials, parts, products or tools
Work that needs one or more steps
Work that makes you wait
Searching, Cleaning up messes, repairs, tune ups,
slow operations, sorting and inspections
65. 68
MUDA – WASTE
Questions to be asked to detect WASTE
5W - 1H
What for ? (Purpose)
What is that ?
What is it for ?
What would happen if that operation was
eliminated ?
What else should be done ?
Why ? (Necessity)
Why is it necessary ? Why that way ?
Why is that being done ?
66. 69
MUDA – WASTE
5 W – 1 H
Where ? (Place)
Where is the location ? Why there ?
Can it be changed ? Can it be combined at one
place ?
When ? (Sequence)
Why at that time ?
When it is reasonable ?
Who ? ( Operator)
Who is that ? Why he does that open ?
Are many people doing the same job ?
67. 70
MUDA WASTE
5 W – 1 H
How ? (Method)
Why is it being done this way ?
Is that the best way to do it ?
Can it be done another way ?
How much will it cost ?
68. 71
MURA – INCONSISTENCY
Uneven Color, texture or material
thickness
General irregularity non uniformity or
nonconfirmity
Inconsistency sometimes result due to
addition of personal touch
69. 72
MURA – IRRATIONALITIES
Inadequacies
Things that are hard to reach or
difficult to do
Things that don’t make sense or
are hard to find reasons for
Things we do because told to do
70. 73
KAIZEN Vs INNOVATION
Parameter Kaizen Innovation
Effect
Pace
Time Frame
Change
Involvement
Approach
Mode
Spark
Long term & long lasting Short term but dramatic
Small Steps Big steps
Continuous & Incremental Intermittent & non-incremental
Gradual & constant Volatite
Everybody Selected
Collectivism, group efforts &
systems approach
Individual Ideas & efforts
Maintenance & Improve Scrap & rebuild
Convention Know-how New tech, new theories
71. 74
WHEN KAIZEN ?
Whenever there is a
1. Pain area for individual
2. Pain area for Organization
3. Dissatisfaction over working method
72. 75
PROBLEM IDENTIFICATION
What is a problem ?
It’s the deviation from the norm
Difference between what’s expected & what
is actually occuring
Reducing or eliminating the difference
between the two is solving the problem.
All improvements start with the perception of
a problem as a deviation from the ideal.
74. 77
WHERE TO DO KAIZEN ?
One’s own work area : Routine / Non-
routine
Common relevant area : Own / Other
Dept.
Other’s work area : Reception / Pantry
More importantly : One’s own personal
area : HOME
75. 78
AREAS FOR KAIZEN
COST
SAFETY
MAINTENANCE
WASTE
INADEQUACY
ENERGY
SERVICE
PRODUCTIVITY
TRUST
INCONSISTENCY
76. 79
HOW TO DO KAIZEN
Use of 5-W & 1-H
SCARE
Value-Added
Non-Value Added
PDCA
WHY WHY ANALYSIS
77. 80
5W & 1H METHOD
WHAT
What is wrong ?
What is causing problem ?
WHERE
Where is the problem ?
Area, Location etc.
WHO
Who does it ?
Who is responsible for this ?
WHEN
When does it happen ?
WHY
Why does it happen ?
Why do we do it this way ?
HOW
How else could it be done ?
How to improve the situation
78. 81
SCARE
S – simplify
C – combine
A – add
R – rearrange
E - eliminate
79. 82
VA/NVA ANALYSIS
Draw process flow charts
Identify whether value-added
Analyze reasons for NVA activities
Eliminate NVA activities
New method of working
81. 84
PRINCIPLE OF PDCA
Every time a new measure is
implemented, it must be seen
how it goes, check the results,
search out and admit mistakes
and try to do better in the next
attempt.
82. 85
WHY WHY ANALYSIS
Why did the machine stop ?
There was an Overload.
Why was there an overload ?
The bearing was not sufficiently lubricated
Why was it not lubricated sufficiently ?
The lubrication pump was not pumping sufficiently
Why was pump not pumping sufficiently ?
The shaft of the pump was warn out and rattling.
Why was the shaft worn out ?
There was no Stainer attached & metal scrap got
in.
83. 86
KAIZEN CULTURE
People are free to make mistakes.
People should admit mistakes.
Process-oriented thinking, along with result-oriented.
People work in a collaborative manner with mutual trust.
Emphasize what is wrong, rather than who.
Make decisions with data, not ad-hoc.
Subscribe to marketing concept (customer concept).
You are surrounded by mountains of treasures (problems).
Improvement starts from home.
Never fail to standardize.
85. 88
GOLDEN RULES FOR IMPROVEMENT
Do not make an excuse.
Think about how to do it, not how to explain
it.
Don’t be afraid of trying, due to fear of
failure.
Do it now.
Do not seek perfection. 60% is good enough
to move forward.
Try Try And try.
86. 89
GOLDEN RULES FOR IMPROVEMENT
Replace activities that do not contribute to
profits with ones that do.
Time is the shadow of motion.
Do not use money. Use your head. If you
cannot use your head, sweat it out.
There is always room for improvement.
Management is starting with planning and
comparing it with results (PDCA cycle).
87. 90
FUNDAMENTALS OF IMPROVEMENT
Start with small improvements
Start with one problem, not others
Start with an easy area
Improvement is a part of daily routine
Collect group wisdom
Never accept status quo
Never reject any Idea before trying
Highlite Problems don’t hide them